Current regulator apparatus and methods

ABSTRACT

An apparatus according to the present invention provides regulated pulsed current to an LED from a voltage source such as a rectified AC voltage. The present inventions provide methods for delivering regulated pulsed current to an LED from the voltage source.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 11/805,952filed May 25, 2007 and claims the benefit and priority of U.S.provisional patent application No. 60/808,881 filed on May 26, 2006, thedisclosures of each are hereby incorporated by reference in theirentirely.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present inventions relate to electrical circuits and, moreparticularly, circuits for operation of light emitting diodes.

2. Brief Description of the Related Art

A step down voltage regulator is commonly used in systems that use highinput voltages such as 24V, 48V, 120V or higher that must be locallyconverted to a lower voltage such as 15V, 12V or 5V with very littlepower loss. A Buck regulator is an example of a DC to DC step-downvoltage regulator. The Buck regulator, unlike linear dissipativeregulators, can be used to step DC voltage down to a lower DC voltage ofthe same polarity. For stable DC input voltages such as in batterypowered systems, traditional Buck regulators provide a very efficientform of power conversion from higher to lower voltages.

A Buck regulator in electrical communication with a discontinuous DCvoltage source is illustrated in FIG. 1. The Buck regulator takesadvantage of the energy storage characteristics of two passivecomponents, a capacitor for voltage storage and an inductor for currentstorage. The Buck regulator alternates between two modes of operation,an ON mode and an OFF mode. In the ON mode, the capacitor, the inductor,and the LED are connected to the source voltage, which charges theinductor and the capacitor and powers the LED. In the OFF mode, thecapacitor, the inductor, and the LED are disconnected from voltagesource, and the inductor and the capacitor are discharged into the LED.

However, Buck regulators may have some disadvantages. Voltage ripple isthe phenomenon where die voltage rises during the ON mode and fallsduring the OFF mode. Several factors contribute to voltage rippleincluding, but not limited to, switching frequency, capacitance, load,and any current limiting features of the control circuitry. At the mostbasic level, the output voltage will rise and fall as a result of thecharging and discharging of the capacitor. Qualitatively, as thecapacitance increases, the magnitude of the voltage ripple decreases.The capacitance is generally limited by cost, physical size andnon-idealities of various capacitor types. The magnitude of the voltageripple also decreases as the switching frequency increases. However, theability to increase the switching frequency is limited. Switching lossesreduce efficiency, and non-ideal switching characteristics of thefree-wheeling diode can also reduce efficiency and may raise EMIconcerns.

When the voltage source is a rectified AC voltage with a sinusoidalwaveform, the switching frequency may be based on the frequency of thevoltage source. A large capacitance may be required to reduce ripple toan allowable level. Buck regulators typically use an electrolyticcapacitor to reduce voltage ripple to the allowable level. However, theuse of electrolytic capacitors introduces several parasitic elementswhich can make buck regulator performance less than ideal. Largeelectrolytic capacitors have a large equivalent series resistance (ESR)which directly affects the performance and efficiency of any switchingregulator. Electrolytic capacitors have high ESR because the dielectriccontains a liquid-based electrolyte. At low operating temperatures, theESR of a typical aluminum electrolytic may increase by 40 times as thetemperature drops from 25° C. to −40° C., which will typically cause thecapacitor to quit working. At high temperatures and/or high operatingcurrent, the liquid present in the capacitor may evaporate and the ESRincreases due to internal heat generation. Unfortunately, as the ESRgoes up, so does the internal heat generation, which can cause thecapacitor to fail. In extreme cases, the electrolyte can actually boiland cause the capacitor to explode.

A light emitting diode (LED) may operate in two different modes, eithera constant current mode, which is the most common, or a pulsed currentmode. In the constant current mode, a constant DC current is deliveredto the LED. In the pulsed current mode, pulses of regulated current aredelivered to the LED. The pulsed current mode with specified maximumduty cycle and maximum pulse width is recommended by majority of the LEDmanufacturers, because the LED may cool between pulses, which mayprolong the life of the LED.

Accordingly, a need exists for a device that may deliver a regulatedpulsed current to an LED, and that may avoid the problems associatedwith devices such as Buck regulators.

SUMMARY OF THE INVENTION

Apparatus and methods in accordance with the present invention mayresolve many of the needs and shortcomings discussed above and provideadditional improvements and advantages as will be recognized by thoseskilled in the art upon review of the present disclosure.

An apparatus according to the present invention provides regulatedpulsed current from a constant polarity discontinuous DC voltage sourcesuch as a rectified AC voltage. The apparatus may include a regulatingunit. The regulating unit is operable in a power mode and in a setbackmode. In the power mode, the regulating unit may receive current fromthe voltage source and flow the current onto an LED. The apparatus mayalso include a switch control in electronic communication with theregulating unit to control the regulating unit in order to flowregulated current onto the LED during the power mode. The switch controlmay also place the regulating unit in the setback mode. Substantially nocurrent flows onto the LED during the setback mode.

The present inventions may also include methods for providing regulatedpulsed current from a constant polarity discontinuous DC voltage source.The methods may include providing a regulating unit, the regulating unitallowing current to flow onto an LED from a voltage source, andproviding a switch control. The methods may include determining asetback mode and a power mode, and the switch control controlling theregulating unit thereby allowing a regulated current to flow onto theLED during the power mode. The methods may further include providing aninductor and a switch electrically communicating in series with the LEDin the regulating unit. Regulating the current flow onto the LED bycharging the inductor from the voltage source and discharging currentfrom the inductor onto the LED by toggling the switch between an ONstate and an OFF state may also be included in the methods according tothe present inventions. Determining the power mode and the setback modefrom the waveform of the voltage source may also be included in themethods.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates a schematic diagram of a Buck regulator;

FIG. 2A illustrates a schematic diagram of an exemplary embodiment of anapparatus in accordance with the present inventions;

FIG. 2B illustrates another schematic diagram of an exemplary embodimentof an apparatus in accordance with the present inventions;

FIG. 3A illustrates a timing diagram of the switch state in an exemplaryembodiment of an apparatus in accordance with the present inventions;

FIG. 3B illustrates a timing diagram of the current in the regulatingunit of an exemplary embodiment of an apparatus in accordance with thepresent inventions;

FIG. 3C illustrates a timing diagram of the waveform of the voltagesource in an exemplary embodiment of an apparatus in accordance with thepresent inventions;

FIG. 4A illustrates a schematic diagram of an exemplary embodiment of anapparatus in accordance with the present inventions;

FIG. 4B illustrates a schematic diagram of an exemplary embodiment of aduty cycle control of an apparatus in accordance with the presentinventions;

FIG. 4C illustrates a schematic diagram of an exemplary embodiment of azero cross detector of an apparatus in accordance with the presentinventions;

FIG. 5A illustrates a timing diagram of the waveform of the voltagesource in an exemplary embodiment of an apparatus in accordance with thepresent inventions;

FIG. 5B illustrates a timing diagram of the zero cross detector signalin an exemplary embodiment of an apparatus in accordance with thepresent inventions;

FIG. 5C illustrates a timing diagram of the delay pulse generator signalin an exemplary embodiment of an apparatus in accordance with thepresent inventions;

FIG. 5D illustrates a timing diagram of the duty cycle control signal inan exemplary embodiment of an apparatus in accordance with the presentinventions;

FIG. 5E illustrates a timing diagram of the switch state in an exemplaryembodiment of an apparatus in accordance with the present inventions;

FIG. 6A illustrates a timing diagram of the switch state in an exemplaryembodiment of an apparatus in accordance with the present inventions;

FIG. 6B illustrates a timing diagram of the timing signal in anexemplary embodiment of an apparatus in accordance with the presentinventions;

FIG. 6C illustrates a timing diagram of the current in the regulatingunit of an exemplary embodiment of an apparatus in accordance with thepresent inventions;

FIG. 6D illustrates a timing diagram of the current sensor signal in anexemplary embodiment of an apparatus in accordance with the presentinventions;

FIG. 7 illustrates a schematic diagram of an exemplary embodiment of anapparatus in accordance with the present inventions.

DETAILED DESCRIPTION OF THE INVENTION

An apparatus 10 according to the present invention provides regulatedpulsed current from a constant polarity discontinuous DC voltage source100 to an LED 30. The apparatus 10 may operate in a power mode and asetback mode. During the power mode, the apparatus 10 flows regulatedcurrent onto the LED 30. Substantially no current flows onto the LED 30in the setback mode. The apparatus 10 is configured to alternate betweenthe power mode and the setback mode in order to provide regulated pulsecurrent to the LED

The power mode and the setback mode may correspond to portions of thewaveform of the voltage source 100. The apparatus 10 may toggle betweenthe setback mode and the power mode so that regulated pulses of currentare provided to the LED 30 only when sufficient voltage is available atthe voltage source 100. For example, the setback mode may correspond toportions of the waveform generally below a threshold voltage V_(mn).Portions of the waveform generally above the threshold voltage V_(mn)may then generally correspond to the power mode.

The Figures generally illustrate exemplary embodiments of apparatus 10and methods which include aspects of the present inventions. Theparticular embodiments of the apparatus 10 which are illustrated in theFigures have been chosen for ease of explanation and understanding ofvarious aspects of the present inventions. The extension of the Figuresand schematics with respect to number, position, relationship,capacities and dimensions of the components to form the devices will beexplained or will be within the skill of the art after the followingdescription has been read and understood. Further, the exactconfiguration and components necessary to conform to specificperformance requirements will likewise be within the skill of the artafter the following description has been read and understood. Theillustrated embodiments are not meant to limit the scope of coverage butinstead to assist in understanding the context of the language used inthis specification and the appended claims. Accordingly, many variationsfrom the illustrated embodiments may be encompassed by the appendedclaims.

The apparatus 10 according to the present invention may include avoltage source 100 having a constant polarity, a regulating unit 20, anda switch control 70. The regulating unit 20 and the switch control 70may be in electrical communication with the voltage source 100. Theapparatus 10 is configured to deliver regulated pulsed current derivedfrom the voltage source 100 to the LED 30.

The voltage source 100 is a constant polarity discontinuous DC voltagesource such as, for example, a rectified AC voltage. The AC voltage maybe mains electric or may be a low voltage AC voltage that may be steppeddown by transformer from mains electric. The AC voltage may typicallyrange up to about 400V with a typical frequency range of from about 40to 60 Hz although the frequency may be as high as around 400 Hz. Invarious aspects, a half-bridge rectifier, a full bridge rectifier, orother known rectifier may be used to rectify the AC voltage, and,accordingly, the voltage supplied by the voltage source 100 may have thewave form of a sinusoidal wave in positive quadrants with a periodrelated to the period of the AC voltage supplied to the rectifier. Invarious other aspects, the voltage supplied by the voltage source 100may have any of a variety of wave forms depending upon the nature of thevoltage source 100, as would be readily recognized by those skilled inthe art upon review of this disclosure.

The regulating unit 20 is configured to receive current from the voltagesource 100 and to flow current onto the LED 30. The regulating unit 20is operable in a power mode and in a setback mode and the regulatingunit 20 may be placed in the power mode and placed in the setback modein order to provide regulated pulsed current onto the LED 30. In variousaspects, the regulating unit 20 may include an inductor 50, the LED 30,a switch 60, and a free-wheel diode 40. The regulating unit 20 may be inelectronic communication with the voltage source 100 so that currentfrom the voltage source 100 flows onto the regulating unit 20. Invarious aspects, the regulating unit 20 is configured to deliver aregulated current from the voltage source 100 to the LED 30 bymodulating the switch 60 to charge the inductor 50 and discharge theinductor 50 through the LED 30. In various aspects, the regulating unit20 is configured to toggle between the setback mode and the power modeto deliver regulated pulsed current to the LED 30 generally during thepower mode.

The inductor 50 may be a single inductor 50 or a plurality of inductorsconfigured to provide an inductance to the regulating unit 20. In theregulating unit 20, the inductor 50 is connected in series with the LED(Load?) 30 so that current stored in the inductor 50 may flow onto theLED 30.

The LED 30 may be any LED, and may include a plurality of LED's. The LED30 is typically configured to provide lighting. However, the LED 30 mayalso be various other loads or combinations of loads as would berecognized by those skilled in the art upon review of this disclosure.

The switch 60 is included in the regulating unit 20 to control the flowof current from the voltage source 100 onto the LED 30. The switch 60has two states, an ON state and an OFF state, and the switch 60 may betoggled between the ON state and the OFF state. When the regulating unit20 is in electrical communication with the voltage source 100, currentis allowed to flow onto the LED 30 from the voltage source 100 when theswitch 60 is placed in the ON state. Substantially no current is allowedto flow onto the LED 30 from the voltage source 100 when the switch isplaced in the OFF state. The switch 60 may be a transistor such as aMOSFET, an electromechanical switch, or other switch as would berecognized by those skilled in the art upon review of this disclosure.

The switch control 70 is configured to communicate with the switch 60 tothe regulating unit 20 in the setback mode, to place the regulating unit20 in the power mode, and to control the regulating unit to deliverregulated current onto the LED 30 during the power mode. The switchcontrol 70 is configured to communicate a switch control signal to theswitch 60, so that the switch control 70 may place the switch 60 in theON state and in the OFF state.

In order to provide the regulated current pulse to the LED 30 during thepower mode, the switch control 70 may toggle the switch 60 between theON state and the OFF state to charge the inductor 50 and then dischargethe inductor 50 onto the LED 30, respectively. In the ON state, currentmay flow from the voltage source 100 onto the LED 30 and through theinductor 50 to charge the inductor 50. When the current reaches themaximum regulated current I_(mx), the switch 60 may be placed in the OFFstate. Current ceases to flow from the voltage source 100 onto the LED30, but current may then flow onto the LED 30 from the inductor 50through the freewheel diode 40 until the inductor 50 is generallydischarged to the preset limit. Placement of the switch 60 in the ONstate again allows current to flow from the voltage source 100 onto theLED 30 and to charge the inductor 50.

Substantially no current flows onto the LED 30 from the voltage source100 when the switch 60 is placed in the OFF state. Accordingly, the OFFstate may correspond to the setback mode, and the switch control 70 mayplace the regulating unit in the setback mode by placing the switch 60in the OFF state.

The free-wheel diode 40 may be any suitable diode, transistor basedswitch, or other high speed switch to force the current to flow from thevoltage source 100 onto the LED 30 and through the inductor 50 when theswitch 60 is placed in the ON state, while allowing current to flow fromthe inductor 50 onto the LED 30 when the switch 60 is placed in the OFFstate. In some aspects, the free-wheel diode 40 could be configured as atransistor or other high speed switch that is alternated between an ONstate and an OFF state generally in unison with the switch 60.

The apparatus 10 according to the present invention further includes theswitch control 70. The switch control 70 places the switch 60 in the OFFstate and the ON state in order to place the regulating unit 20 in thesetback mode and the power mode. In the power mode, the switch control70 toggles the switch 60 between the OFF state and the ON state in orderto regulate the current flow onto the LED 30.

In various aspects, the switch control 70 may toggle the switch 60between the OFF state and the ON state to toggle the apparatus 10between the setback mode and the power mode in response to a duty cyclesignal from a duty cycle control 170. In the power mode, the switchcontrol 70 may toggle the switch 60 between the OFF state and the ONstate in response to a current sensor signal from a current sensor unit110 and a timing signal from a clock 130 in order to provide regulatedpulsed current to the LED 30. In other aspects, the switch control 70may be keyed to various other signals indicative of states of theapparatus 10 including the current within the regulating unit 20 aswould be recognized by those skilled in the art upon review of thisdisclosure. The switch control 70, in various aspects, may be inelectrical communication with the voltage source 100 to derive powerfrom the voltage source 100 and to ascertain various states such as thewaveform of the voltage source 100.

The switch control 70 may, in various aspects, include the duty cyclecontrol 170 configured to generate duty cycle control signals sequencedto the waveform of the voltage source 100. The duty cycle controlsignals may be indicative of the setback mode and power mode, and maycause the switch control 70 to place the apparatus 10 in the setbackmode or in the power mode. Accordingly, the duty cycle control 170 maygenerate a duty cycle control signal configured as at least a first dutycycle control signal and a second duty cycle control signal. In variousaspects, the first duty cycle control signal may be indicative of thesetback mode, and the second duty cycle control signal may be indicativeof the power mode. The duty cycle control signal may, in certainaspects, be a logical signal, for example, with 0 corresponding to thefirst duty cycle control signal (low) and, hence, indicative of thesetback mode, and 1 corresponding to the second duty cycle controlsignal (high) and, hence, indicative of the power mode.

In various aspects, the duty cycle control 170 may sequence the firstduty cycle control signal and the second duty cycle control signal tovarious portions of the waveform of the voltage source 100, so that thesetback mode and the power mode correspond to the portions of thewaveform of the voltage source 100. For example, the duty cycle control170 may generate a second duty cycle control signal generally proximateto the maxima of the waveform and a first duty cycle control signalgenerally corresponding to the remaining portions of the waveform. As afurther example, in aspects wherein the voltage source 100 has asinusoidal waveform in positive quadrants, the first duty cycle controlsignal indicative of the setback mode may generally correspond toportions of this sinusoidal waveform below a threshold voltage V_(mn).The second duty cycle control signal indicative of the power mode maygenerally correspond to portions of this sinusoidal waveform above thethreshold voltage V_(mn).

The current sensor unit 110 senses the current in the regulating unit 20and generates a current sensor signal. In various aspects, the currentsensor signal could be an analogue or digital signal indicative of thecurrent flowing through the regulating unit 20. For example, in someaspects, the current sensor signal may be a logic signal with a highvalue corresponding to 1 and a low value corresponding to 0.Accordingly, the current sensor signal 0 could be generated by thecurrent sensor unit 110 when the current flowing through the LED 30equals or exceeds the maximum regulated current I_(mx). The currentsensor signal 1 could be generated by the current sensor unit 110 whenthe current in the regulating unit 20 is less than I_(mx).

The switch control 70 may include the clock 130 which may be configuredas an oscillator or suchlike that generates a timing signal. In variousaspects, the timing signal may be configured as a logical signal with afirst timing signal and a second timing signal. In various aspects, thefirst timing signal may be low (o) and the second timing signal may behigh (1). The timing signal frequency may be related to the timerequired to charge the inductor 50 or to the time required to dischargethe inductor 50 in various aspects, and the timing signal frequency maybe chosen in order to provide a regulated current to the LED 30. Theswitch control 70, in various aspects, may toggle the switch 60 betweenthe ON state and the OFF state in correspondence to the first timingsignal and the second timing signal. In some aspects, the switch control70 may toggle the switch 60 between the ON state and the OFF stategenerally at the timing signal frequency.

The switch control 70 may be in electrical communication with the switch60. In various aspects, the switch control 70 may generate a switchcontrol signal alterable between at least a first switch control signalto place the switch 60 in the OFF state and a second switch controlsignal to place the switch 60 in the ON state. For example, the switchcontrol signal maybe configured as a binary signal with the first switchcontrol signal equated to 0 (low) and the second switch control signalequated to 1 (high).

In some aspects, the switch control 70 may use a logical gate 190 suchas a logic AND gate to generate the switch control signal. For example,the duty control signal, the timing signal, and the current sensorsignal may be configured as logical signals that may be input into thelogical gate 190. The logical gate 190 may then generate the switchcontrol signal configured as a binary signal. The logical gate 190 maygenerate the second switch control signal when the duty cycle control170 generates the second duty cycle control signal, the timing signalequates the second timing signal, and the current sensor signal equatesto 1. Otherwise, the logical gate 190 may generate the first switchcontrol signal. The duration of each first switch control signal and/oreach second switch control signal generated by the logical gate 190 maycorrespond to the duration of the timing signal from the clock 130.Accordingly, in this example, the logical gate 190 can only generate thesecond switch control signal, which corresponds to the power mode, whenthe duty cycle control 170 generates the second duty cycle controlsignal. The logical gate 190 could generate the first switch controlsignal, which corresponds to the setback mode, only when the duty cyclecontrol 170 generates the first duty cycle control signal.

In various aspects, the logical gate 190 may be a logic OR gate orvarious other logic gates as would be recognized by those skilled in theart upon review of this disclosure. It should also be understood thatthe various logical signals in various aspects of the apparatus 10including the timing signal, the current sensor signal, switch controlsignal, and the duty cycle control signal may be adapted such that thelow signal and the high signal are variously indicative. For example, insome aspects, the duty cycle control signal could be a logical signalwith 0 corresponding to the first duty cycle control signal (low) and,hence, indicative of the setback mode, and 1 corresponding to the secondduty cycle control signal (high) and, hence, indicative of the powermode. In other aspects, the duty cycle control signal could be a logicalsignal with 1 corresponding to the first duty cycle control signal(high) and indicative of the setback mode, and 0 corresponding to thesecond duty cycle control signal (low) and indicative of the power mode.

In aspects having the switch 60 configured as a transistor, the switchcontrol 70 may be in electrical communication with the transistor gateto communicate the switch control signal to the transistor gate. Theswitch 60 may be placed in the ON state by, for example, the switchcontrol 70 applying a high voltage corresponding to the second switchcontrol signal to the transistor gate. Application of the high voltagecorresponding to the second switch control signal to the gate causes thesource and the drain of the transistor to be electrically connected.Accordingly, the switch 60 is in the ON state, and current flows fromthe voltage source 100 through the regulating unit 20. The switch 60 maybe placed in the OFF state by, for example, the switch control 70applying a substantially zero voltage corresponding to the first switchcontrol signal to the transistor gate. Accordingly, the source and thedrain are disconnected, so that the switch 60 is in the OFF state. Nocurrent flows from the voltage source 100 through the regulating unit20.

Specific embodiments of the apparatus 10 according to the presentinventions are illustrated in the Figures. An apparatus 10 according tothe present invention is illustrated in the schematic diagrams of FIGS.2A and 2B. As illustrated, the apparatus 10 includes the regulating unit20 and the switch control 70 in electrical communication with thevoltage source 100. The voltage source 100 supplies power to theregulating unit 20. The regulating unit 20, as illustrated in FIGS. 2Aand 2B, includes the inductor 50, the LED 30, the switch 60, and thefree-wheel diode 40. Current may flow onto the LED 30 from the voltagesource 100 when the switch 60 is in the ON state. Substantially nocurrent flows onto the LED 30 from the voltage source 100 when theswitch 60 is in the OFF state, but current may flow onto the LED 30 fromthe inductor 50 through the free-wheel diode 40.

The switch control 70, in this embodiment, is in electricalcommunication with the regulating unit 20 including the switch 60 and onthe low side of the switch 60. As illustrated, the switch control 70 maybe in electronic communication with the voltage source 100. The switchcontrol 70 may toggle the switch 60 between the ON state and the OFFstate to provide the regulated pulse of current in the power mode byflowing current onto the LED 30 from the voltage source 100, anddischarging current from the inductor 50 through the free-wheel diode 40onto the LED 30, respectively. The switch control 70 may toggle theswitch 60 into the OFF state in order to enter the setback mode and maymaintain the switch 60 in the OFF state throughout the duration of thesetback mode to maintain the apparatus 10 in the setback mode.

Current flows in response to the state of the switch 60 during the powermode are illustrated in FIGS. 2A and 2B. In FIG. 2A, the switch 60 istoggled to the ON state by the switch control 70. With the switch 60 inthe ON state, current flows as indicated by the arrows from the voltagesource 100 onto the LED 30, through the inductor 50, and through theswitch 60 to ground 150. The free-wheel diode 40 is reverse biased sothat there is substantially no current flow across the free-wheel diode40. When the switch 60 is toggled into the ON state, the current throughthe inductor 50, which has inductance L, may generally rise an amount ΔIin time interval Δt according to:

ΔI=(V _(in) −V _(LED 30))Δt/L

where V_(in) is the voltage supplied by the voltage source 100 andV_(LED) is the voltage drop (forward voltage) across the LED 30.

In FIG. 2B, the switch 60 is toggled to the OFF state by the switchcontrol 70, so that the regulating unit 20 is disconnected from ground150 and current is no longer supplied to the regulating unit 20 from thevoltage source 100. The free-wheel diode 40 becomes forward biased, sothat current flows from the inductor 50, through the free-wheel diode40, and onto the LED 30. The current through the inductor 50 maygenerally drop an amount ΔI in time interval Δt according to:

ΔI=−V _(LED 30) Δt/L

The minimum value for the voltage V_(in) should be at least 2 timeshigher than the forward voltage of the LED 30 for high efficiencyoperation. For example, if V_(in)=2V_(LED), then the current through theinductor 50 will rise and fall the same amount ΔI in the same timeinterval Δt. By toggling the switch 60 between the OFF state and the ONstate in such a way that the switch 60 is held in the OFF state for timeinterval Δt and held in the ON state for time Δt, the current throughthe circuit would generally fall an amount ΔI below the regulatedcurrent I_(mx) and then rise to I_(mx), respectively.

FIGS. 3A, 3B, and 3C illustrate the switch state, the current throughthe inductor 50, and the waveform of the voltage source 100,respectively, in an embodiment of an apparatus 10 according to thepresent inventions. As illustrated by comparing FIGS. 3A and 3B, as theswitch 60 is toggled between the OFF state and the ON state, the currentthrough the inductor 50 may fall an amount ΔI below the regulatedcurrent I_(mx) in time interval Δt, and then rise a corresponding amountΔI to the regulated current I_(mx) during the power mode. The timeinterval Δt, the inductance L and the ripple ΔI are interrelated. Forexample, the ripple ΔI below the regulated current I_(mx) may bedecreased by increasing the inductance L of the inductor 50 or bydecreasing the time interval Δt. By decreasing the time interval Δt, asmaller inductance L, and, hence, a smaller inductor 50 would berequired to control the ripple ΔI within desirable limits.

The power mode and the setback mode are also illustrated by FIGS. 3A,3B, and 3C for an embodiment of an apparatus 10 according to the presentinventions. As illustrated in FIGS. 3A and 3B, during the power mode,the regulated pulse of current is supplied to the LED 30 by toggling theswitch 60 between the ON state and the OFF state. During the setbackmode, the switch 60 is held in the OFF state, as illustrated in FIG. 3A,so that substantially no current flows onto the LED 30, as illustratedin FIG. 3B. As illustrated in FIG. 3C, the power mode and the setbackmode may be sequenced to the waveform of the voltage source 100. Asillustrated in FIG. 3C, the power mode may be initiated when the voltagegenerally exceeds the minimum voltage V_(m) and the setback mode may beinitiated when the voltage drops generally below the minimum voltageV_(m). Accordingly, in this embodiment, the regulated pulse of currentis flowed onto the LED 30 generally only during the power mode when thevoltage supplied by the voltage source 100 exceeds the minimum voltageV_(m).

An embodiment of an apparatus 10 according to the present inventionsincluding the regulating unit 20 and switch control 70 is illustrated inFIGS. 4A, 4B, and 4C. In this illustrated embodiment, the switch control70 includes clock 130, current sensor unit 110, duty cycle control 170,and logical gate 190.

The clock 130, in this embodiment, continuously generates a highfrequency timing signal configured as a logical signal, which may rangein frequency from several kHz to several MHz. The frequency of thetiming signal is limited by the maximum switching frequency of theswitch 60. If a MOSFET or similar device is used for the switch 60, thetiming signal frequency may be several MHz. The higher the timing signalfrequency, the smaller the inductance L that is required to maintain astable regulated current in the circuit. The timing signal is input tothe logical gate 190 in this embodiment.

The current sensor unit 110 may sense the current at a point in theregulating unit 20, for example, the current to ground 150 on the lowside of the switch 60, as illustrated in FIG. 4A. The current sensorunit 110 generates a current sensor signal indicative of the current andconfigured as a logic signal in this embodiment. If for example, thecurrent reaches or exceeds the upper current limit I_(max), the currentsensor unit 110 may generate the low signal (0). If the current dropsbelow 1, the sensor generates the high signal (1). The current sensorsignal is input to the logical gate 190 in this embodiment.

The duly cycle control 170 generates the duty cycle control signal tosignal the setback mode and the power mode. In this embodiment, the dutycycle control signal is configured as a logical signal with the lowsignal (0) corresponding to the first duty cycle control signal andindicative of the setback mode, and the high signal (1) corresponding tothe second duty cycle control signal and indicative of the power mode.In this embodiment, the duty cycle control 170 may generate the secondduty cycle control signal generally proximate to the maxima of thewaveform of the voltage source 100, and a first duty cycle controlsignal generally proximate to the remaining portions of the waveform.

In the embodiment illustrated in FIG. 4A, the timing signal, the currentsensor signal, and the duty cycle control signal are input into thelogical gate 190. The logical gate 190 may then generate the switchcontrol signal configured as a binary signal. The logical gate 190output signal, in this particular embodiment, is a logic signalgenerated by the logical gate 190 based on the truth table given inTable 1 below. According to this truth table, the logical gate 190generates the second switch control signal only when the timing signalequates to 1, the current sensor signal equates to 1, and the duty cyclecontrol 170 generates the second duty cycle control signal (1).Otherwise, the logical gate 190 generates the first switch controlsignal.

In the embodiment of current invention illustrated in FIG. 4A, theswitch 60 is configured as a MOSFET. The switch control signal passesfrom the logical gate 190 to the MOSFET gate. A high logical gate 190output signal corresponding to the second switch control signal appliesvoltage to the MOSFET gate, and allows current to flow between thesource and the drain, so that the switch 60 is in the ON state. A lowlogical gate 190 output signal corresponding to the first switch controlsignal electrically disconnects the source and the drain. Substantiallyno current flows between the source and the drain, so that the switch 60is in the OFF state.

TABLE 1 TRUTH TABLE FOR LOGICAL GATE Logic Signal From Switch controlDuty Cycle Clock Current sensor Signal (logical gate control 170 130unit 110 190 output signal) 1 0 0 0 1 1 0 0 1 0 1 0 1 1 1 1 0 1 1 0 0 01 0 0 0 0 .0 0 1 0 0

An embodiment of the duty cycle control 170 that generates the firstduty cycle control signal and the second duty cycle control signalindicative of the setback mode and the power mode, respectively, basedupon the waveform of the voltage source 100 is illustrated in the blockdiagram of FIG. 4B. The duty cycle control 170, in the embodimentillustrated in FIG. 4B, includes a zero cross detector 174, a delaypulse generator 178, and a logical signal generator 182. The zero crossdetector 174 generates a zero cross detector signal when the voltage atthe voltage source 100 is substantially zero in this embodiment. Thezero cross detector signal is communicated to the delay pulse generator178. The delay pulse generator 178 then generates a delay pulsegenerator signal at a fixed time delay t_(D) from the zero crossdetector signal in this embodiment. The delay pulse generator signal iscommunicated to the logical signal generator 182.

The logical signal generator 182 generates the duty cycle control signalconfigured as a logical signal with the low signal (0) corresponding tothe first duty cycle control signal and the high signal (1)corresponding to the second duty cycle control signal in thisembodiment. In this embodiment, the first duty cycle control signal isindicative of the setback mode, and the second duty cycle control signalis indicative of the power mode. The logical signal generator 182generates the second duty cycle control signal for a specified durationt_(L) upon receipt of the delay pulse generator signal. After durationt_(L), the duty cycle control 170 generates the first duty cycle controlsignal. In various embodiments, the second duty cycle control signal maycorrespond to maxima of the waveform of the voltage source 100 or totime periods where voltage V_(in) is generally greater than or equal toV_(mn). The duty cycle control signal is then input to the logical gate190.

FIG. 4C illustrates an embodiment of the zero cross detector 174. Inthis embodiment, the zero cross detector 1′74 is in electroniccommunication with the voltage source 100 configured as a rectified ACvoltage. The zero cross detector 174, as illustrated, generates the zerocross detector signal with a frequency twice that of the AC line voltagefrequency. For example, if the AC line voltage frequency is 60 Hz, thezero cross detector 174 will generate 120 zero cross detector signalsper second. The zero cross detector signal is communicated to the delaypulse generator 178.

After receiving the zero cross detector signal, the delay pulsegenerator 178 then generates a delay pulse generator signal at a presettime delay t_(D) from the zero cross detector signal in this embodiment.The time delay t_(D) may be chosen so that the delay pulse generatorsignal generally coincides with the peak of the waveform of the voltagesource 100. For a sinusoidal waveform, this value for t_(D) generallycorresponds to a phase angle of 90 degrees. In various embodiments, thetime delay t_(D) may be chosen so that the delay pulse generator signalgenerally coincides with other portions of the waveform, for example,that correspond to a minimum voltage V_(mn). A peak voltage generatormay be used as the delay pulse generator 178 in some embodiments. Thedelay pulse generator signal is communicated to the logical signalgenerator 182.

After receiving the delay pulse generator signal, the logical signalgenerator 182 generates the second duty cycle control signal. Theduration t_(L) of the second duty cycle control signal generated, inthis embodiment, by the logical signal generator 182 corresponds to theduration of the power mode. For example, for a voltage source 100 thatis a fully rectified 60 Hz line voltage, the period of one cycle is 8.3ms. For a power mode with a duration of 10%, the duration t_(L) of theduly cycle control signal is 830 μs. The duty cycle control signal maymatch the frequency of the voltage source 100. After time t_(L) thelogical signal generator 182 reverts to generating the first duty cyclecontrol signal. The duty cycle control signal may be input to thelogical gate 190, in this illustrated embodiment.

The sequence of signals in the embodiment of the duty cycle control 170illustrated in FIG. 4B including the signals from the zero crossdetector 174, the delay pulse generator 178, and the logical signalgenerator 182, is illustrated in FIGS. 5A to 5E and in FIGS. 6A to 6D.The state of the switch 60 is illustrated in FIG. 5E and in FIG. 6A. Asillustrated in FIG. 5A, the voltage source 100 in this embodiment is afully rectified AC voltage source that has the form of a rectified sinewave with twice the frequency of the AC voltage source. The zero crossdetector 174 generates the zero cross detector signal generally at thezero points of the discontinuous DC voltage, as illustrated in FIG. 5B.The delay pulse generator 178 then generates the delayed pulse generatorsignal, which is delayed by delay time t_(D) from the zero crossdetector signal, as illustrated in FIG. 5C. The delay time t_(D) may bechosen so that the signal generated by the delay pulse generator 178occurs generally near the leading portions of the peaks of thediscontinuous DC voltage. The duty cycle control signal generated by thelogical signal generator 182 may have a duration t_(L), where t_(L) maybe chosen so that the logical signal generally coincides with the peakof the waveform, as illustrated in FIG. 5D. As illustrated in FIG. 5E,the switch control 70 may toggle the switch 60 to generated theregulated current only during the duration t_(L) of the second dutycycle control signal, which corresponds to the power mode. The switch 60is maintained in the OFF state during the first duty cycle controlsignal, which corresponds to the setback mode.

FIGS. 6A to 6D illustrate the sequence of signals during the power modein the embodiment of FIGS. 4A to 4C. As illustrated in FIGS. 6A and 6B,as the timing signal is alternated between 0 and 1, the switch 60 isalternated between the OFF state and the ON state in correspondence.When the switch 60 is in the ON state, the regulating unit 20 isconnected to ground 150 so that current flows onto the LED 30 from thevoltage source 100, and current is stored in the inductor 50. When theswitch 60 is in the OFF state, the inductor 50 is discharged onto theLED 30 through free-wheel diode 40, and the current drops in regulatingunit 20. An example of the current ripple about the maximum regulatedcurrent I_(max) is illustrated in FIG. 6C. The current sensor signalwhich is triggered when the current reaches I_(max) is also illustratedin FIG. 6D.

A schematic of an exemplary embodiment of an apparatus 10 according tothe present invention is illustrated in FIG. 7. In this figure, thevoltage source 100 is an AC voltage rectified by a full bridge rectifierand applied to LED's 30 a, 30 b. A capacitor 210 may be included tofilter high frequency voltage noise. In this embodiment, the currentsensor unit 110 includes a current sensor 215 in series with an inverter220. The current sensor 215 generates a current sensor signal configuredas a logic signal with a high value (1) corresponding to the currentequaling or exceeding the upper current limit I_(max). If the currentdrops below I_(max), the current sensor unit 110 generates the lowsignal (0). The current sensor 215 could be, for example, a currentsense resistor connected to a voltage comparator IC. In this embodiment,the signal from the current sensor is inverted by an inverter 220 inorder to generate the current sensor signal, with a low value (0)indicative of current equaling or exceeding the upper current limitI_(max) and the high value (0) indicative of the current below I_(max).The current sensor signal in then input to the logical gate 190, asillustrated.

In the embodiment of FIG. 7, the free-wheel diode 40 in the regulatingunit 20 is configured as a transistor 4) having a gate in communicationwith the switch control 70 through an inverter 220. The inverter 220inverts the switch control signal, so that the connection between thegate and the drain of the transistor 41 is open when the switch 60 is inthe ON state and the gate and the drain of the transistor 41 are inelectrical communication when the switch 60 is in the OFF state.

The present inventions may also include methods for providing aregulated pulsed current from a voltage source 100. The methods mayinclude providing a voltage source 100 and providing a regulating unit20 having a switch 60 with an ON state and an OFF state, an LED 30, aninductor 50, and a free-wheel diode 40. The method may includedetermining a setback mode and a power mode. The method may furtherinclude charging the inductor 50 with the discontinuous DC current anddischarging the inductor 50 into the LED 30 by toggling the switch 60between the ON state and the OFF state during the power mode. Themethods may further include maintaining the switch 60 in the OFF stateduring the setback mode so that substantially no current flows onto theLED 30 from the voltage source 100 during the setback mode. By providingregulated current to the LED 30 during the power mode and by no currentflowing onto the LED 30 from the voltage source 100 during the setbackmode, the methods may provide a regulated pulsed current to the LED 30.

The methods may further include the setback mode and the power modecorresponding to portions of the waveform of the voltage source 100.

In various aspects, the methods may include providing a switch control70 to control the state of the switch 60 by toggling the switch 60between the ON state and the OFF state. In some aspects, the methods mayfurther include configuring the switch control 70 from a clock 130, acurrent sensor unit 110, a duty cycle control 170, and a logical gate190. In some aspects, the methods may further include configuring theduty cycle control 170 from a zero cross detector 174, a delay pulsegenerator 178, and a logical signal generator 182.

Although the present invention has been described with reference topreferred embodiments, those skilled in the art will recognize changesthat may be made in form and detail without departing from the spiritand scope of the invention.

What is claimed is:
 1. An apparatus, comprising: a regulating unit, theregulating unit operable in a power mode and in a setback mode, theregulating unit configured to receive current from a voltage source, theregulating unit flows current onto an LED during the power mode; aswitch control in electronic communication with the regulating unit tocontrol the regulating unit to flow regulated current onto the LEDduring the power mode and to flow substantially no current onto the LEDduring the setback mode, wherein the switch control comprises: a currentsensor unit, the current sensor unit generating a current sensor signalindicative of the current in the regulating unit, and wherein the switchcontrol is configured to generate a switch control signal in response tothe current sensor signal, the switch control signal toggles the switchbetween the ON state and the OFF state, wherein the regulating unitcomprises: a switch, the switch having an ON state and an OFF state, theswitch in the ON state allows the LED to receive current from thevoltage source, the switch in the OFF state substantially disconnectsthe LED from the voltage source, the switch in electronic communicationwith the switch control such that the switch control may place theswitch in the ON state and in the OFF state; an inductor, the inductorin electronic communication with the LED, the inductor in the electroniccommunication with the switch, the inductor stores current from thevoltage source when the switch is in the ON state, current flows fromthe inductor onto the LED when switch is in the OFF state; and a currentsensor unit, the current sensor unit generating a current sensor signalindicative of the current in the regulating unit, wherein the switchcontrol is configured to generate a switch control signal in response tothe current sensor signal, the switch control signal toggles the switchbetween the ON state and the OFF state.
 2. The apparatus, as in claim 1,further comprising: a diode, the diode configured to three the currentto flow from the voltage source onto the LED and through the inductorwhen the switch is in the ON state, while allowing current to flow fromthe inductor onto the LED when the switch is in the OFF state.
 3. Theapparatus, as in claim 2, wherein the diode is a free-wheel diodeconfigured as a transistor.
 4. The apparatus, as in claim 1, furthercomprising: the switch control configured to place the switch in the ONstate and the OFF state to provide regulated current flow from thevoltage source onto the LED during the power mode, and to place theswitch in the OFF state to substantially disconnect the LED from thevoltage source during the setback mode.
 5. The apparatus, as in claim 1,wherein the power mode and the setback mode are sequenced to thewaveform of the voltage source.
 6. The apparatus, as in claim 1, whereinthe switch control comprises: the current sensor unit, the currentsensor unit generating a current sensor signal indicative of the currentin the regulating unit; a clock, the clock generating a timing signal;and a duty cycle control, the duty cycle control generates a duty cyclecontrol signal indicative of the power mode and the setback mode;wherein the switch control configured to generate the switch controlsignal in response to the current sensor signal, the timing signal, andthe duty cycle control signal, the switch control signal toggles theswitch between the ON state and the OFF state.
 7. The apparatus, as inclaim 6, further comprising: a logical gate, the current sensor signal,the timing signal, and the duty cycle control signal input to thelogical gate, the logical gate generates the switch control signal. 8.The apparatus, as in claim 6, wherein the duty cycle control comprises:a zero cross detector, the zero cross detector in electroniccommunication with the voltage source, the zero cross detector generatesa zero cross detector signal when the voltage source voltage issubstantially zero, a delay pulse generator, the delay pulse generatorin electronic communication with the zero cross detector such that thezero cross detector signal is communicated to the delay pulse generator,the delay pulse generator generates a delay pulse generator signalsequenced to the zero cross detector signal; and a logical signalgenerator, the logic signal generator in electronic communication withthe delay pulse generator such that the delay pulse generator signal iscommunicated to the logical signal generator, the logical signalgenerator generates the duty cycle control signal sequenced to the delaypulse generator signal.
 9. A method, comprising: providing a regulatingunit, the regulating unit allowing current to flow onto an LED from avoltage source; providing a switch control; determining a setback modeand a power mode; controlling the regulating unit by the switch controlthereby allowing a regulated current to flow onto the LED during thepower mode; providing in the regulating unit an inductor and a switchelectrically communicating in series with the LED; regulating thecurrent flow onto the LED by charging the inductor from the voltagesource and discharging current from the inductor onto the LED bytoggling the switch between an ON state and an OFF state; providing acurrent sensor unit, a clock, and a duty cycle control in the switchcontrol; generating a current sensor signal indicative of the current inthe regulating unit by the current sensor unit; and generating a switchcontrol signal in response to the current sensor signal the switchcontrol signal placing the switch in the ON state and the OFF state. 10.The method, as in claim 9, further comprising: sequencing the power modeand the setback mode with the wave form of the voltage source.
 11. Themethod, as in claim 9, further comprising: generating a timing signal bythe clock; and generating a duty cycle control signal indicating thepower mode and the setback mode by the duty cycle control; wherein thestep of generating a switch control signal in response to the currentsensor signal includes generating a switch control signal in response tothe current sensor signal the timing signal, and the duty cycle controlsignal, the switch control signal placing the switch in the ON state andthe OFF state.
 11. The method, as in claim 11, further comprising:providing a logical gate; inputting the current sensor signal into thelogical gate; inputting the timing signal into the logical gate;inputting the duty cycle control signal into the logical gate; andgenerating the switch control signal by the logical gate.